Visual inspection device

ABSTRACT

A visual inspection device includes a body having a support portion and a grip portion extending from the support portion. The device also includes a flexible cable having a first end portion coupled to the body and a second end portion, and a camera assembly coupled to the second end portion of the flexible cable. The camera assembly includes an image sensor operable to transmit image data through the flexible cable. The device further includes a display supported by the support portion of the body. The display is electrically connected to the flexible cable to display image date from the image sensor. The device is powered by a rechargeable battery pack removably coupled to the body.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.14/666,448, filed Mar. 24, 2015, now U.S. Pat. No. 9,693,024, which is acontinuation of U.S. patent application Ser. No. 14/182,230, filed Feb.17, 2014, now U.S. Pat. No. 8,988,522, which is a continuation of U.S.patent application Ser. No. 13/470,824, filed May 14, 2012, now U.S.Pat. No. 8,659,652, which is a continuation of U.S. patent applicationSer. No. 12/399,755, filed Mar. 6, 2009, now U.S. Pat. No. 8,189,043,which claims the benefit of U.S. Provisional Patent Application No.61/034,801, filed Mar. 7, 2008, the entire contents of all of which arehereby incorporated by reference.

BACKGROUND

The present invention relates to a visual inspection device and, moreparticularly, to a hand-held visual inspection device for viewingconfined or otherwise difficult to access locations.

Visual inspection devices (e.g., borescopes, endoscopes, or the like)provide tradespeople (e.g., plumbers, electricians, mechanics, HVAC(heating, ventilation, and air conditioning) professionals, welders,carpenters, MRO (maintenance, repair, and operations) professionals, orthe like) with means to view locations that are inaccessible withoutdismantling or removing surrounding structures. For example, visualinspection devices are used to inspect inside pipes, walls, floors,aircraft or automobile engines, or other equipment that include narrow,small, and/or dark passageways. Some visual inspection devices have alsobeen employed by surgeons to help view inside patients during, forexample, surgery.

SUMMARY

In one embodiment, the invention provides a visual inspection devicethat includes a body, a flexible cable, a camera assembly, a display, abattery terminal, and a rechargeable battery pack. The body includes asupport portion and a grip portion extending from the support portion.The grip portion defines a first axis. The flexible cable includes afirst end portion coupled to the body and a second end portion. Thefirst end portion defines a second axis. The camera assembly is coupledto the second end portion of the flexible cable, and the camera assemblyincludes an image sensor. The image sensor is operable to transmit imagedata through the flexible cable. The display is supported by the supportportion of the body and is electrically connected to the flexible cableto display images captured by the image sensor. The display defines adisplay plane. The battery terminal is supported by the grip portion,and the battery terminal is electrically connected to at least one ofthe image sensor and the display. The rechargeable battery pack includesa coupling mechanism that engages the body to releasably secure thebattery pack to the body. A portion of the battery pack is engageablewith the battery terminal, and the battery terminal is generally exposedwhen the battery pack is not secured to the body. The first axisintersects the display plane at a first angle, the second axisintersects the first axis at a second angle, the second axis intersectsthe display plane at a third angle, and the first angle is less than thethird angle.

In another embodiment, the invention provides a system of electricaldevices that includes a visual inspection device and a removable andrechargeable battery pack. The visual inspection device includes a body,a flexible cable, a camera assembly, a display, and a battery terminal.The body includes a support portion and a grip portion extending fromthe support portion. The grip portion defines a first axis. The flexiblecable includes a first end portion coupled to the body and a second endportion. The first end portion defines a second axis. The cameraassembly is coupled to the second end portion of the flexible cable andincludes an image sensor. The image sensor is operable to transmit imagedata through the flexible cable. The display is supported by the supportportion of the body and is electrically connected to the flexible cableto display images captured by the image sensor. The display defines adisplay plane. The battery terminal is electrically connected to atleast the display. The first axis intersects the display plane at afirst angle, the second axis intersects the first axis at a secondangle, the second axis intersects the display plane at a third angle,and the first angle is less than the third angle. The removable andrechargeable battery pack is configured to be coupled to and providepower to the inspection device. The removable and rechargeable batterypack includes a coupling mechanism that engages the body to releasablysecure the battery pack to the body, and a portion of the battery packis engageable with the battery terminal.

Other aspects of the invention will become apparent by consideration ofthe detailed description and accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a visual inspection device according toone embodiment of the invention.

FIG. 2 is a side view of the visual inspection device shown in FIG. 1without a flexible cable and a camera assembly.

FIG. 3 is a rear view of the visual inspection device of FIG. 2.

FIG. 4 is an end perspective view of the visual inspection device ofFIG. 2 with a battery pack separated from the video inspection device.

FIG. 5 is an exploded view of the visual inspection device of FIG. 2.

FIG. 6 is a cross-sectional view of the visual inspection device takenalong section line 6-6 of FIG. 3.

FIG. 7 is a perspective view of a connector assembly for connecting abody of the visual inspection device to the flexible cable.

FIG. 8 is an exploded view of the connector assembly of FIG. 7.

FIG. 9 is a cross-sectional view of a portion of the connector assemblyof FIG. 7 connected to the body.

FIG. 10 is a cross-sectional view of a portion of the connector assemblyof FIG. 7 connected to the flexible cable.

FIG. 11 is an exploded view of a portion of the flexible cable and thecamera assembly of the visual inspection device.

FIG. 12 is a cross-sectional view of the portion of the flexible cableand the camera assembly of FIG. 11.

FIG. 13 is another cross-sectional view of the portion of the flexiblecable and the camera assembly of FIG. 11.

FIG. 14 is a front view of a display and a portion of the body of thevisual inspection device.

FIG. 15 illustrates a variety of battery life indicia for the display ofFIG. 14.

FIG. 16A is a perspective view of a battery pack for use with the visualinspection device.

FIG. 16B is a perspective view of another battery pack for use with thevisual inspection device.

FIG. 17A is an end view of the battery pack of FIG. 16A.

FIG. 17B is an end view of the battery pack of FIG. 16B.

FIG. 18 is an exploded view of a first connector portion of an extensioncable for use with the visual inspection device.

FIG. 19 is a cross-sectional view of the first connector portion of theextension cable of FIG. 18.

FIG. 20 is an exploded view of a second connector portion of theextension cable.

FIG. 21 is a cross-sectional view of the second connector portion of theextension cable of FIG. 20.

FIG. 22 is a schematic of a digital signal processor for use with thevideo inspection device.

Before any embodiments of the invention are explained in detail, it isto be understood that the invention is not limited in its application tothe details of construction and the arrangement of components set forthin the following description or illustrated in the following drawings.The invention is capable of other embodiments and of being practiced orof being carried out in various ways. Also, it is to be understood thatthe phraseology and terminology used herein are for the purpose ofdescription and should not be regarded as limiting.

DETAILED DESCRIPTION

FIG. 1 illustrates a visual inspection device 30 according to oneembodiment of the present invention. In the illustrated embodiment, thevisual inspection device 30 is a hand-held unit usable by an operator(e.g., a plumber, an electrician, a mechanic, an HVAC professional, awelder, a carpenter, an MRO professional, or the like) to view theinterior of a confined space (e.g., a pipe, a wall, a floor, an engine,or the like). The illustrated visual inspection device 30 includes abody 34, a flexible cable 38 coupled to and extending from the body 34,a camera assembly 42 coupled to the flexible cable 38, and a display 46supported by the body 34. The visual inspection device 30 also includesa battery pack 50 removably coupled to the body 34.

Referring to FIGS. 1-6, the body 34 includes an upper housing 54 and alower housing 58 coupled together in a clamshell manner. The upperhousing 54 and the lower housing 58 at least partially enclose andprotect the display 46, a display control printed circuit board (PCB)62, a switch PCB 66, and battery terminals 70. The upper and lowerhousings 54, 58 define a grip portion 78 configured to be grasped by auser and a support portion 82 configured to support the display 46. Asshown in FIGS. 2 and 3, the grip portion 78 includes a contour 86, orrecess, formed in the lower housing 58 to facilitate holding the device30 during operation. An elastomeric overmold 90, 94, or skin, is coupledto each of the upper housing 54 and the lower housing 58 to facilitategripping of the support portion 82 and to help protect the body 34 ifthe device 30 is banged into a surface or dropped.

As shown in FIGS. 4 and 5, the support portion 82 defines an opening 98formed in the upper housing 54. In the illustrated embodiment, theopening 98 is generally square and allows the display 46 positionedwithin the support portion 82 to be visible through the upper housing54. In other embodiments, the opening 98 may be rectangular, circular,or the like to complement a shape of the display 46.

As shown in FIG. 2, an upper surface 102 of the support portion 82defines a display plane 104. The display plane 104 is angled relative toa grip axis 106 extending through the grip portion 78 such that thedisplay 46 is tilted toward the grip portion 78 or actuators 112-122(described below; i.e., away from the contour 86), and thereby toward auser operating the device 30. The illustrated grip axis 106 extendslongitudinally through grip portion 78 from a first end of the gripportion 78 supporting the battery pack 50 to a second end adjacent tothe support portion 82. In the illustrated embodiment, the display plane104 intersects the grip axis 106 at an acute angle α. In someembodiments, the angle α may be between, for example, about 5° and about25°. Such an orientation facilitates viewing images on the display 46while holding the device 30 at the grip portion 78. In otherembodiments, the support portion 82 may be tilted in the oppositedirection such that the display 46 is tilted toward the contour 86 andaway from the actuators 112-122.

Referring to FIGS. 1, 2, and 5, the illustrated support portion 82 alsoincludes a cover member 107 (e.g., an elastomeric flap) positioned overan output port 108 (FIG. 5) and a card slot 109 (FIG. 5). The outputport 108 and the card slot 109 facilitate connection of removable memoryunits and other external devices to the device 30. For example, in someembodiments, the output port 108 is a USB port that receives a removableflash drive or a USB cable to connect the device 30 directly to acomputer or external monitor. Similarly, in some embodiments, the cardslot 109 is configured to receive, for example, a secure digital (SD)card to store images and videos captured by the camera unit 250.

Referring to FIG. 5, the upper housing 54 also defines a plurality ofapertures 110 corresponding to a plurality of actuators 112, 114, 116,118, 120, 122 extending from the switch PCB 66 and out of the housing54. The illustrated actuators 112-122 are elastomeric buttons used toinitiate or control operating functions of the visual inspection device30. In the illustrated embodiment, the first actuator 112 is a powerbutton to turn the device 30 ON and OFF, the second actuator 114 is avideo button to enter a video mode for recording video clips with thecamera assembly 42, the third actuator 116 is a photo button to enter aphoto mode for capturing still photos with the camera assembly 42, andthe fourth actuator 118 is a playback button to enter a playback modefor displaying the recorded video clips or captured still photos on thedisplay 46. The fifth actuator 120 is a menu or execute button forentering a menu mode of the device 30 and initiating other functions ofthe device 30. For example, in the menu mode, a user may zoom in or panacross an image, rotate images or videos displayed on the display 46,adjust the brightness or intensity of a light source 126 (FIGS. 12 and13) in the camera assembly 42, delete or transfer saved data to a remotedevice, and control various settings of the device 30. The directionalbuttons 122 surrounding the menu button 120 allow a user to cyclethrough the different menus and adjust the settings of the device 30when in a particular mode. In other embodiments, the visual inspectiondevice 30 may include fewer or more actuators operable to controldifferent operating functions of the device 30.

In the illustrated embodiment, the body 34 supports a microphone 128 anda speaker 129. The illustrated microphone 128 is positioned on thesupport portion 82 adjacent to the display 46. The microphone 128picks-up and records audio commentary from a user during operation ofthe device 30. In other embodiments, a microphone may also oralternatively be supported on the camera assembly 42 to pick up audio ata distal end of the cable 38. The speaker 129 is also positioned on thesupport portion 82, but adjacent to the plurality of actuators 112-122.The speaker 129 outputs the recorded audio from the microphone 128, aswell as other instructions, alerts, and warnings preprogrammed into thedevice 30.

As shown in FIGS. 5 and 6, the body 34 includes a stem 130 extendingfrom the lower housing 58 and a holder 134 positioned within the body 34to couple the stem 130 to the lower housing 58. The stem 130 connects tothe flexible cable 38 to electrically couple the display 46 and thePCB's 62, 66 to the flexible cable 38 and, thereby, to the cameraassembly 42. The holder 134 is securely fastened (e.g., via screws) tothe lower housing 58 and receives a portion of the stem 130. The stem130 includes a flattened surface portion 138 (FIG. 7) corresponding to aD-shaped opening 140 (FIG. 5) in the holder 134 to inhibit rotation ofthe stem 130 relative to the body 34 and to ensure proper alignment ofthe stem 130 in the holder 134 during assembly. In the illustratedembodiment, a nut 142 engages a threaded portion 146 of the stem 130 toinhibit the stem 130 from sliding or being pulled out of the holder 134,thereby securing the stem 130 to the body 34. An elastomeric member 150(e.g., an O-ring) is positioned between the stem 130 and the lowerhousing 58 adjacent to the holder 134 to help waterproof the body 34.

Referring to FIG. 2, the stem 130 defines a stem axis 152 extendinglongitudinally through the stem 130. The illustrated stem axis 152intersects both the grip axis 106 and the display plane 104 at anoblique angle. In particular, the stem axis 152 intersects the grip axis106 at a first oblique angle β₁ and intersects the display plane 104 ata second oblique angle β₂. In the illustrated embodiment, the firstangle β₁ is between about 50° and about 70° and the second angle β₂ isbetween about 60° and 80°.

As shown in FIG. 1, the flexible cable 38 is coupled to the stem 130 ofthe body 34. The flexible cable 38 supports a plurality of wires toelectrically couple the display 46 and the PCB's 62, 66 to the cameraassembly 42. The illustrated cable 38 is sufficiently rigid to maintainits shape, yet flexible enough to bend around corners and through, forexample, pipes where necessary. In some embodiments, such as theillustrated embodiment, the cable 38 is composed of carbon steel andcovered or coated with a polyvinyl chloride (PVC) skin to decreasefriction between the cable 38 and the surrounding environment (e.g., apipe surface), as well as to help waterproof the cable 38. In theillustrated embodiment, the flexible cable 38 may be, for example, aboutthree feet or about six feet long. In other embodiments, the flexiblecable 38 may be connected to a cable extension to increase the overalllength of the cable 38, as further discussed below.

Referring to FIGS. 7-10, a connector assembly 154 releasably couples theflexible cable 38 to the stem 130. The illustrated connector assembly154 includes a stem connector portion 158 (FIGS. 8 and 9) supported onthe stem 130 and a cable connector portion 162 (FIGS. 8 and 10)supported on the flexible cable 38. As shown in FIGS. 8 and 9, the stemconnector portion 158 includes an electrical connector 166, or dinreceptacle, positioned substantially in an end of the stem 130 oppositethe threaded portion 146. In the illustrated embodiment, the electricalconnector 166 is a 9-pin connector and is secured in place with a setscrew 170. The stem connector portion 158 also includes a collar 174, orsleeve, slidably coupled to the stem 130. The collar 174 engages thecable connector portion 162 to securely connect the stem connectorportion 158 and the cable connector portion 162 together. An elastomericmember 178 (e.g., an O-ring) is positioned between the stem 130 and thecollar 174 to help waterproof the connector assembly 154. In someembodiments, a cavity 182 in the stem 130 may be filled through a port186 with a potting compound to help waterproof the stem 130 and securethe electrical connector 166 in place.

As shown in FIGS. 8 and 10, the cable connector portion 162 includes anadaptor 190 securely mounted (e.g., press fit) on a first end portion194 of the cable 38, a plug connector 198 threadably coupled to theadaptor 190, and an electrical connector 202, or din receptacle,positioned substantially within the plug connector 198. The illustratedelectrical connector 202 is a 9-pin connector configured to mate withthe electrical connector 166 of the stem connector portion 158 and issecured in place with a set screw 206. The illustrated plug connector198 includes a threaded portion 210 configured to be engaged by athreaded portion 214 of the collar 174 to secure the cable connectorportion 162 to the stem connector portion 158. The plug connector 198also includes a tongue 218 configured to be received in a correspondingrecess 222 formed in the stem 130 to inhibit rotation of the cableconnector portion 162 relative to the stem connector portion 158. Anelastomeric member 226 (e.g., an O-ring) is positioned adjacent to thethreaded portion 210 of the plug connector 198 to help waterproof theconnector assembly 154. In some embodiments, a cavity 230 in the plugconnector 198 between the electrical connector 202 and the cable 38 maybe filled through ports 234 with a potting compound to help waterproofthe connector assembly 154 and secure the plug connector 198 and theelectrical connector 202 in place.

As shown in FIGS. 1 and 11-13, the camera assembly 42 is coupled asecond end portion 242 of the flexible cable 38 opposite the connectorassembly 154. The illustrated camera assembly 42 includes a generallycylindrical housing 246, a camera unit or image sensor 250, the lightsource 126, and a lens 254. In the illustrated embodiment, the cameraunit 250 and the light source 126 are mounted adjacent to an end of thehousing 246 on a first printed circuit board (PCB) 258. A second PCB 262extends perpendicularly from the first PCB 258 to electrically couplethe wires extending through the flexible cable 38 to the camera unit 250and the light source 126. The illustrated camera unit 250 may be, forexample, a CCD (charge coupled device) or a CMOS (complementary metaloxide semiconductor) operable to capture an image and transfer imagedata through the wires to the display 46. In the illustrated embodiment,the image data is transferred from the camera unit 250 to the display 46digitally, as further discussed below. Transferring the image datadigitally requires less energy and, therefore, increases the runtime ofthe device 30.

The illustrated light source 126 is a white light emitting diode (LED)extending from the first PCB 258 and beyond the camera unit 250. Inother embodiments, the camera assembly 42 may include multiple LED'sextending from the PCB 258 and/or may include different types of lightsources. The light source 126 provides illumination to an area aroundthe camera unit 250. In the illustrated embodiment, the brightness, orintensity, of the light source 126 is controlled by a user operating thedevice 30. For example, a setting in the menu mode allows the user toadjust the light intensity between a low, a medium, and a highbrightness setting by depressing one or more of the correspondingdirectional buttons 122 (FIG. 1).

The lens 254 is coupled to the end of the housing 246 to cover andprotect the camera unit 250 and the light source 126. In someembodiments, such as the illustrated embodiment, the lens 254 isultrasonic welded or brazed to the housing 246. As shown in FIGS. 11-13,the lens 254 includes a protrusion 266 to accommodate the additionalheight of the light source 126 and to help focus, or direct, the lightemitted from the light source 126 to an area of interest adjacent to thecamera unit 250.

With continued reference to FIGS. 11-13, the flexible cable 38 includesan adaptor 270 securely mounted (e.g., press fit) on the second endportion 242 of the cable 38 opposite the connector assembly 154 and acamera connector 274 threadably coupled to the adaptor 270. The cameraconnector 274 includes a threaded portion 278 configured to engage acorresponding threaded portion 282 of the camera housing 246 to securethe camera assembly 42 to the cable 38. A set screw 286 extends throughthe camera connector 274 to further secure the camera assembly 42relative to the cable 38. As shown in FIGS. 12 and 13, an elastomericmember 290 (e.g., an O-ring) is positioned between the camera housing246 and the camera connector 274 adjacent to the threaded portions 278,282 to help waterproof the camera assembly 42. In some embodiments, acavity 294 in the camera connector 274 between the housing 246 of thecamera assembly 42 and the cable 38 may be filled through a port 298(FIG. 12) with a potting compound to further help waterproof the cameraassembly 42 and to secure the camera assembly 42 to the flexible cable38.

As shown in FIG. 5, the display 46 includes a lens 302 and a liquidcrystal display (LCD) 306 operable to display images captured by thecamera unit 250. The display 46 is positioned within the support portion82 of the body 34 such that the LCD 306 is visible through the opening98 in the upper housing 54. The lens 302 is positioned within theopening 98 to cover and protect the LCD 306. In the illustratedembodiment, the lens 302 is made of a clear polycarbonate material. TheLCD 306 is electrically coupled to the display control unit PCB 62 toreceive image data from the camera unit 250. The LCD 306 is alsoelectrically coupled to the switch PCB 66 to receive operating functionsinitiated by a user (e.g., power ON/OFF, zoom, pan, etc.). Operation ofthe camera unit 250 and the LCD 306 are discussed in more detail belowwith reference to FIG. 22.

Referring to FIGS. 14 and 15, the LCD 306 not only displays images fromthe camera unit 250, but also displays indicia relating to the operationof the visual inspection device 30. For example, as shown in FIG. 14,the LCD 306 displays a battery life indicator 310 and a zoom indicator314. The battery life indicator 310 helps a user identify approximatelyhow much battery power (e.g., voltage) is left in a battery pack coupledto the device 30. As shown in FIG. 15, the illustrated battery lifeindicator 310 displays four different indicators relating to fourdifferent battery lives (e.g., a full battery life indicator 310A, a ⅔battery life indicator 310B, a ⅓ battery life indicator 310C, and anempty or charge battery indicator 310D). In some embodiments, the chargebattery indicator 310D may blink or flash when displayed. Although notillustrated, the LCD 306 may also display other types of indicia. Theillustrated LCD 306 displays a different indicator to notify a user ifthe device 30 is currently in the video record mode, the still photomode, or the playback mode. In addition, when the device 30 enters themenu mode, the LCD 306 will display menu identifies relating to thevarious options and settings available for the device 30. Furthermore,the LCD 306 may also disclose other types of informative indicia, suchas the current date and time, the amount of memory left in an internalor removable disk, or the like.

Referring back to FIG. 14, the zoom indicator 314 identifies the currentzoom setting on the LCD 306. Actuating (e.g., depressing) thedirectional buttons 122, when in the proper menu setting, allows a userto change between the various zoom settings. In the illustratedembodiment, the zoom function cycles between 1.0× zoom and 4.0× zoom by0.1× (i.e., ten percent) increments. In other embodiments, the zoomfunction may zoom up to, for example, 5.0× or 10.0× zoom, and/or thezoom function may increase and decrease by different increments (e.g.,0.05×, 0.25×, 0.5×, 1.0×, or the like). In the illustrated embodiment,the zoom function digitally zooms in on an image displayed on the LCD306. In other embodiments, actuating the zoom button 122 may physicallyalter or adjust the camera unit 250 to zoom in on an area of interest.When zoomed in on an image, the directional buttons 122 also allow auser to pan across the image, when in the proper menu setting.

Referring to FIGS. 1-6, the battery pack 50 is removably coupled to thebody 34 to provide power to the camera assembly 42 (e.g., the cameraunit 250 and the light source 126), the LCD 306, and the PCB's 62, 66,258, 262. In the illustrated embodiment, the battery pack 50 is arechargeable power tool battery pack that is usable with a variety ofpower tools (e.g., drills, screwdrivers, saws, or the like). The batterypack 50 is insertable into a cavity 318 (FIG. 4) formed in an end of thegrip portion 78 substantially opposite the support portion 82. As shownin FIG. 2, the battery pack 50 is inserted along the grip axis 106extending through the grip portion 78.

Referring to FIGS. 4 and 5, the battery pack 50 includes a batterycasing 322 enclosing one or more battery cells, an outer housing 326coupled to the casing 322, and a coupling mechanism. The battery casing322 fits within the cavity 318 and supports receptacles 330 configuredto engage and electrically connect to the battery terminals 70. Thereceptacles 330 and the casing 322 substantially enclose and cover thebattery terminals 70 when the casing 322 is positioned within the cavity318. However, the grip portion 78 does not include a cover or end capsuch that, when the casing 322 is removed from the cavity 318, thebattery terminals 70 are generally exposed to the surroundingenvironment.

The outer housing 326 surrounds the battery casing 322 and is positionedoutside of the cavity 318 when the casing 322 is inserted into the gripportion 78. As shown in FIGS. 1-3, the outer housing 326 is generallyshaped and sized to match the contours of the grip portion 78 such that,when the casing 322 is positioned within the cavity 318, the outerhousing 326 defines a portion of the grip portion 78. That is, the outerhousing 326 of the battery pack 50 mates with the upper and lowerhousings 54, 58 of the body 34 to generally extend the length of thegrip portion 78.

The coupling mechanism of the battery pack 50 includes two actuators 334and two tabs 338 to releasably secure the battery pack 50 to the body34. In the illustrated embodiment, the actuators 334 and the tabs 338are formed as a single piece with the outer housing 326. The tabs 338engage corresponding recesses 340 (one of which is shown in FIG. 4). Dueto the resiliency of the material forming the outer housing 326, thetabs 338 are normally biased away from the battery casing 322 to engagethe recesses 340. Actuating (e.g., depressing) the actuators 334 movesthe tabs 338 out of engagement with the recesses 340 such that thebattery pack 50 may be pulled away from the body 34. This arrangementallows a user to quickly remove the battery pack 50 from the device forrecharging or replacement without the use of tools. In addition, theillustrated coupling mechanism allows the battery pack 50 to beself-secured to the body 34 of the device 30 and does not require anadditional cover and/or fastening member to hold the battery pack 50within the cavity 318.

FIGS. 16A-17B illustrate two such battery packs 50A, 50B usable with thevisual inspection device 30. The battery packs 50A, 50B aresubstantially similar to one another and to the battery pack 50discussed above, and like parts have been given the same referencenumbers plus an ‘A’ or ‘B’ designation.

The battery pack 50A illustrated in FIGS. 16A and 17A is a six-volt (6V)alkaline battery pack. The illustrated battery pack 50A includes fouralkaline-based battery cells positioned within the battery casing 322A.In some embodiments, the battery pack 50A may include, for example,standard rechargeable AA batteries, AAA batteries, or the likepositioned within the battery casing 322A. The alkaline battery pack 50Ais operable to power the visual inspection device 30 for about five toten hours of use.

The battery pack 50B illustrated in FIGS. 16B and 17B is a twelve-volt(12V) battery pack. The illustrated battery pack 50B may include threebattery cells having, for example, a lithium (Li), lithium-ion (Li-ion),or other lithium-based chemistry. For example, the battery cells mayhave a chemistry of lithium-cobalt (Li—Co), lithium-manganese (Li—Mn)spinel, or Li—Mn nickel. In such embodiments, each battery cell may havea nominal voltage of about, for example, 3.6V, 4.0V, or 4.2V. In otherembodiments, the battery cells may have a nickel-cadmium, nickel-metalhydride, or lead acid battery chemistry. In further embodiments, thebattery pack 50B may include fewer or more battery cells, and/or eachbattery cell may have a different nominal voltage. The Li or Li-ionbattery pack 50B is operable to power the visual inspection device 30for about fifteen to twenty hours of use.

As shown in FIGS. 17A and 17B, an outer surface portion 342A, 342B ofeach battery casing 322A, 322B (e.g., the top surface in the drawings)has a unique contour. The outer surface portion 342A of the batterycasing 322A shown in FIG. 17A is substantially inclined or sloped, whilethe outer surface portion 342B of the battery casing 322B shown in FIG.17B is substantially planar. Providing two different contours to theouter surface portions 342A, 342B allows both battery packs 50A, 50B tobe inserted into the cavity 318 of the visual inspection device 30, butprevents the battery packs 50A, 50B from being connected to and chargedby an improper battery charger.

As mentioned above, in some embodiments, the flexible cable 38 may beconnected to a cable extension 346 to increase the total length of theflexible cable 38. FIGS. 18-21 illustrate one embodiment of the cableextension 346. The illustrated cable extension 346 may be, for example,a three-foot extension positioned between the body 34 and the flexiblecable 38 to increase the length of the flexible cable 38 from three feetto six feet. In some embodiments, multiple cable extensions 346 may beprovided between the body 34 and the flexible cable 38 (e.g., threethree-foot extensions to increase the total length of the flexible cable38 by nine feet). In the illustrated embodiment, the cable extension 346includes a first connector portion 350 (FIGS. 18 and 19) configured tocouple to the stem connector portion 158 of the connecting assembly 154(FIG. 9) and a second connector portion 354 (FIGS. 20 and 21) configuredto couple to the cable connector portion 162 of the connecting assembly154 (FIG. 10). The illustrated cable extension 346 is composed ofsubstantially the same materials and has approximately the same outerdiameter as the flexible cable 38 such that the cable extension 346performs (e.g., bends) in a substantially similar manner to the flexiblecable 38.

Referring to FIGS. 18 and 19, the illustrated first connector portion350 includes an adaptor 358 securely mounted (e.g., press fit) on afirst end portion 362 of the cable extension 346, a plug connector 366threadably coupled to the adaptor 358, and an electrical connector 370,or din receptacle, positioned substantially within the plug connector366. The illustrated electrical connector 370 is a 9-pin connectorconfigured to mate with the electrical connector 370 of the stemconnector portion 158 (FIG. 9) and is secured in place with a set screw374. The illustrated plug connector 366 includes a threaded portion 378configured to be engaged by the threaded portion 214 of the collar 174(FIG. 9) to secure the cable extension 346 to the stem 130. The plugconnector 366 also includes a tongue 382 configured to be received inthe recess 222 formed in the stem 130 (FIG. 8) to inhibit rotation ofthe cable extension 346 relative to the stem 130. An elastomeric member386 (e.g., an O-ring) is positioned adjacent to the threaded portion 378of the plug connector 366 to help waterproof the first connector portion350. In some embodiments, a cavity 390 in the plug connector 366 betweenthe electrical connector 370 and the extension cable 346 may be filledthrough ports 394 with a potting compound to help waterproof the firstconnector portion 350 and secure the plug connector 366 and theelectrical connector 370 in place.

Referring to FIGS. 20 and 21, the second connector portion 354 includesan adaptor 398 securely mounted (e.g., press fit) on a second endportion 402 of the cable extension 346, an extension connector 406threadably coupled to the adaptor 398, a receptacle connector 410partially received in the extension connector 406, and an electricalconnector 414, or din receptacle, positioned substantially in an end ofthe receptacle connector 410 opposite the extension connector 406. A setscrew 418 extends through the extension connector 406 and engages thereceptacle connector 410 to help secure the receptacle connector 410relative to the extension connector 406. The illustrated electricalconnector 414 is a 9-pin connector configured to mate with theelectrical connector 202 of the cable connector portion 162 (FIG. 10)and is secured in place with a set screw 422.

The second connector portion 354 also includes a collar 426, or sleeve,slidably coupled to the receptacle connector 410 that engages thethreaded portion 210 of the cable connector portion 162 (FIG. 10). Thereceptacle connector 410 includes a recess 430 configured to receive thetongue 218 on the plug connector 198 of the cable connector portion 162(FIG. 8) to inhibit rotation of the flexible cable 38 relative to thecable extension 346. A first elastomeric member 434 (e.g., an O-ring) ispositioned between the receptacle connector 410 and the extensionconnector 406, and a second elastomeric member 438 (e.g., an O-ring) ispositioned between the receptacle connector 410 and the collar 426. Theelastomeric members 434, 438 help waterproof the second connectorportion 354 of the cable extension 346. In some embodiments, a cavity442 in the receptacle connector 410 between the second end portion 402of the cable extension 346 and the electrical connector 414 may befilled through ports 446, 450 with a potting compound to help waterproofthe second connector portion 354 and secure the extension connector 406,the receptacle connector 410, and the electrical connector 414 in place.

As shown in FIG. 22, the video inspection device 30 includes a digitalsignal processor integrated circuit (DSP) 454 for controlling the device30. In the illustrated embodiment, the DSP 454 is at least partiallysupported on the display control PCB 62 (FIG. 5). The DSP 454 includes,among other things, a central processing unit (CPU) 458, a memorymanagement module 462, a video input module 466, a video output module470, a power module 474, a clock generation module 478, a compressionmodule 482, an interface unit (IFU) 486, and a real-time clock (RTC)module 490. The DSP 454 is connected to a plurality of other modules anddevices, such as a camera module 494, a serializer/deserializer 498,500, a volatile memory module 502, the LCD 306 (digital LCD (DLCD)), apower conditioning module 506, a non-volatile memory module 510, and anexternal crystal oscillator 514. The DSP 454 is configured to functionas a digital still camera (DSC) and a digital video camcorder (DVC)device.

The CPU 458 includes memory and is capable of executing computerinstructions fetched from the memory. The CPU 458 is also capable ofretrieving an image or a video stored in memory. Additionally oralternatively, the CPU 458 is coupled to the volatile solid state memory502, such as a synchronous dynamic random access memory (SDRAM) (4 MB)and the non-volatile solid state memory 510, such as a flash memory (16MB). The SDRAM 502 is used for loading and executing computer programapplications stored in the flash memory 510. The flash memory 510 isused for storing executable instructions (software code or applicationprograms) and storing images or video. In some embodiments of theinvention, the interface unit 486 connects additional external memory tothe DSP 454.

The CPU 458 is also connected to the video input module 466 and thevideo output module 470 through the memory management module 462. Thevideo input module 466 receives a digital signal from the camera module494. The digital signal passes through the serializer 498 to produce oneor more serial data streams which can be transmitted through one or morewires in the flexible cable 38. The serial data streams are deserializedin the deserializer 500 before the digital signal is sent to the videoinput module 466. Serializing a signal from the camera module 494reduces the number of wires and signals required between the DSP 454 andthe camera module 494 (for example, a cable reduction of 16:9 or less).The video output module 470 is coupled to the video input module 466through the memory management module 462 and is connected to the LCD306. The LCD 306 is, for example, a 2.4 inch thin film transistor (TFT)display (480×240 resolution). In some embodiments of the invention,alternate types of LCDs are used. The LCD 306 can vary by pixelresolution or color representation methods. For example, in someembodiments, the LCD 306 uses 24-bit truecolor representation, whichallows for over 16 million possible colors for each pixel of the LCD306. The LCD 306 also includes an on-screen display of information. Asmentioned above, the LCD 306 displays the battery life indicator 310 andthe zoom indicator 314. In some embodiments, the LCD 306 may alsodisplay an LED brightness level indicator. In other embodiments of theinvention, the LCD 306 displays additional or alternative information.

The memory management module 462 is coupled to the video input module466, the video output module 470, the SDRAM 502, the flash memory 510(through the IFU 486), the CPU 458, and the compression module 482. Thememory management module 462 is configured to manage memory accessrequests from the CPU 458. The memory management module 462 is capableof managing physical and virtual memory addresses, protecting memory,controlling a cache, and arbitrating access to one or more data buses.The memory management module 462 is configured to, among other things,provide memory space to enable one or more software applications orinstructions to be executed concurrently and to share memory spacebetween different processes within the DSP 454. In some embodiments ofthe invention, the memory management module 462 is coupled to additionalmodules within the DSP 454 and is capable of performing additionalfunctions.

The compression module 482 is coupled to the memory management module462 and is configured to reduce the quantity of data used to represent avideo or an image. The compression module 482 uses, for example, videoor image compression methods approved by the International Organizationfor Standardization (ISO), or the International Telecommunication UnionTelecommunications Standardization Sector (ITU-T). The compressionmodule 482 includes, for example, lossy type image compression and videocompression algorithms.

The power module 474 is coupled to the power conditioning module 506 andreceives a regulated voltage from a voltage source such as, for example,the 6V alkaline battery pack 50A or the 12V lithium-ion battery pack50B. In other embodiments of the invention, different types of batteriesare used. Optionally, the video inspection device 30 includes a wiredpower solution (e.g. a power cable and plug). The power conditioningmodule 506 is, for example, a voltage regulator which receives a DCvoltage of between approximately 5 Volts and approximately 15 Volts. Thepower conditioning module 506 reduces the input DC voltage to a constantlevel (±3%) required by the DSP 454. For example, the DSP 454 mayrequire a constant voltage of 5 Volts or a constant voltage of 3.6Volts. The first actuator 112, or ON/OFF switch, is connected betweenthe power conditioning module 506 and the voltage source (e.g. thebattery pack 50A, 50B). When the ON/OFF switch 112 is in an ON-position,the power conditioning module 506 provides a regulated voltage to theDSP 454. When the ON/OFF switch 112 is in an OFF-position, no energy issupplied to the power conditioning module 506 or the DSP 454.

The clock generation module 478 provides one or more timing signalsrequired by the DSP 454. In some embodiments, the clock generationmodule 478 uses a phase lock loop (PLL) that includes a voltagecontrolled oscillator for producing one or more clock frequenciesrequired by the DSP 454. The external crystal oscillator 514 isconnected to a first input and a second input of the clock generationmodule 478 to provide an external reference frequency of, for example,13.5 MHz. In other embodiments, different types of oscillators anddifferent reference frequencies are used.

The camera module 494 is coupled to the serializer 498 and includes,among other things, the camera unit 250 and the light source 126. Asdiscussed above, the camera unit 250 is, for example, a CMOS sensor (a300K pixels, 30 frames-per-second camera sensor) such as an active pixelsensor or an analog CCD image sensor. In some embodiments, the cameramodule 494 is configured to automatically focus on an object in an imageand to automatically control exposure and white balance in digitalimages and digital video.

The DSP 454 is also coupled to additional input/output ports 518 (I/Oport), such as, for example, a universal serial bus (USB) port. The USBport 518 connects the DSP 454 to an external device such as an externalUSB memory device, a monitor, or a computer.

Although the invention has been described in detail with reference topreferred embodiments, variations and modifications exist within thescope and spirit of one or more independent aspects of the invention asdescribed. Various features and advantages of the invention are setforth in the following claims.

What is claimed is:
 1. A visual inspection device comprising: a bodyincluding a support portion, a grip portion extending from the supportportion, and a stem extending from the support portion; a flexible cableincluding a first end portion and a second end portion; a cameraassembly coupled to the second end portion of the flexible cable, thecamera assembly including an image sensor and a light source, the imagesensor operable to transmit image data through the flexible cable; adisplay supported by the support portion of the body, the displayelectrically coupled to the flexible cable to display images captured bythe image sensor; a battery terminal supported by the grip portion, thebattery terminal being electrically connected to at least the imagesensor, the light source, and the display; and a rechargeable batterypack releasably secured to the body and engaging the battery terminal;and a connector assembly releasably coupling the flexible cable to thestem, the connector assembly including a stem connector portionsupported on the stem, the stem connector portion having a firstelectrical connector positioned substantially in an end of the stem, acollar movably coupled to the stem, and an elastomeric member positionedbetween the stem and the collar, and a cable connector portion supportedon the flexible cable, the cable connector portion having a plugconnector positioned on the first end of the flexible cable and a secondelectrical connector positioned substantially within the plug connectorand configured to mate with the first electrical connector, the plugconnector having a threaded portion that is engaged by a threadedportion of the collar to secure the cable connector portion to the stemconnector portion.
 2. The visual inspection device of claim 1, furthercomprising a holder positioned within the body and receiving a portionof the stem.
 3. The visual inspection device of claim 2, wherein theholder includes a D-shaped opening that receives the stem, and whereinthe stem includes a flattened surface portion corresponding to theD-shaped opening to inhibit rotation of the stem relative to the body.4. The visual inspection device of claim 2, wherein the stem includes athreaded portion extending outwardly from the holder, and furthercomprising a nut threadably engaging the threaded portion of the stem toinhibit the stem from moving out of the holder.
 5. The visual inspectiondevice of claim 1, further comprising an elastomeric member positionedbetween the stem and the body.
 6. The visual inspection device of claim1, wherein the grip portion of the body defines a grip axis extendinglongitudinally through the grip portion, wherein the support portiondefines a display plane that is parallel to the display, wherein thestem defines a stem axis extending longitudinally through the stem, andwherein the stem axis intersects the grip axis and the display plane atan oblique angle.
 7. The visual inspection device of claim 1, whereinthe stem defines a cavity, and wherein the cavity is filled with apotting compound to waterproof the stem.
 8. The visual inspection deviceof claim 1, wherein the cable connector portion further includes anadaptor mounted to the first end portion of the cable and a plugconnector threadably coupled to the adaptor, and wherein the plugconnector includes a threaded portion that is engaged by the collar tosecure the cable connector portion to the stem connector portion.
 9. Thevisual inspection device of claim 8, wherein the stem defines a recess,and wherein the plug connector includes a tongue received in the recessto inhibit rotation of the cable connector portion relative to the stemconnector portion.
 10. The visual inspection device of claim 8, whereinthe cable connector portion further includes an elastomeric memberpositioned adjacent to the threaded portion of the plug connector. 11.The visual inspection device of claim 8, wherein the plug connectordefines a cavity, and wherein the cavity is filled with a pottingcompound to waterproof the connector assembly.
 12. A visual inspectiondevice comprising: a body including a support portion and a grip portionextending from the support portion; a flexible cable including a firstend portion removably coupled to the body and a second end portion; adisplay supported by the support portion of the body, the displayelectrically coupled to the flexible cable; a battery terminal supportedby the grip portion, the battery terminal being electrically connectedto at least the flexible cable and the display; a rechargeable batterypack releasably secured to the body and engaging the battery terminal;and a camera assembly coupled to the first end portion of the flexiblecable, the camera assembly including a generally cylindrical housing, afirst printed circuit board positioned within the generally cylindricalhousing, a second printed circuit board positioned within the generallycylindrical housing, the second printed circuit board extendinggenerally perpendicularly from the first printed circuit board towardthe first end portion of the flexible cable, the second printed circuitboard being electrically coupled to the flexible cable, an image sensormounted on the first printed circuit board, a light source mounted onthe first printed circuit board, and a lens coupled to an end of thegenerally cylindrical housing to cover the image sensor and the lightsource.
 13. The visual inspection device of claim 12, wherein the imagesensor includes a charge coupled device or a complementary metal oxidesemiconductor.
 14. The visual inspection device of claim 12, wherein thelight source includes a light emitting diode.
 15. The visual inspectiondevice of claim 14, wherein the lens includes a protrusion that receivesat least a portion of the light emitting diode.
 16. The visualinspection device of claim 12, wherein the lens is ultrasonic welded orbrazed to the housing.
 17. The visual inspection device of claim 12,wherein the camera assembly further includes a camera connectorsupported by the flexible cable and having a threaded portion coupled toa threaded portion of the housing.
 18. The visual inspection device ofclaim 17, wherein the flexible cable includes an adaptor mounted on thesecond end portion, and wherein the camera connector is threadablycoupled to the adaptor.
 19. The visual inspection device of claim 17,wherein the camera assembly further includes an elastomeric memberpositioned between the camera housing and the camera connector.
 20. Thevisual inspection device of claim 17, wherein the camera connectordefines a cavity, and wherein the cavity is filled with a pottingcompound to waterproof the camera assembly.